Rotary electrical interconnect device

ABSTRACT

A rotary device for providing continuous electrical connections between dynamic, rotationally engaged connector components. The rotary device includes a rotor assembly comprising a plurality of slip ring elements electrically connected to a connector or cable at the rotor end of the device. The rotary device also includes a stator assembly configured to receive the rotor assembly, with slide contacts electrically connected to a connector or cable at the stator end of the device. The rotor assembly is rotationally coupled to the stator assembly, and the slip rings and slide contacts maintain electrical contact during rotation of the rotor assembly relative to the stator assembly. A first electronic device and a second electronic device connected using the rotary device can be freely rotated without twisting of the cable between the two devices. A method for assembling a rotary device configured based on the devices to be connected.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/721,433 (Atty. Docket No. 59977-0650), filed on Nov. 1, 2012, whichis hereby incorporated by reference in its entirety.

BACKGROUND

1. Field

The present invention relates generally to electrical connectors andimprovements thereto. More particularly, the present invention relatesto rotary electrical interconnect devices that are configured tomaintain an electrical connection through a rotatable interface.

2. Description of the Related Art

Electrical connectors that permit one component of the connector torotate with respect to a second component of the connector whilemaintaining an electrical connection between the components are used ina variety of technical fields and applications. These connections,referred to as slip rings, are employed in applications such as cablereels, turbines, motors, remote video devices, robotics, and otherdevices requiring transmission of electrical power or signal through arotating or rotatable electrical connection system.

Slip rings transfer electrical signals through a rotatable electricalcontact using a conductive ring mounted on a rotary member. Theconductive ring is in sliding contact with a conductive brush mounted toa second component of the connector. Rotating electrical connectorshaving various configurations based on this type of electrical contacthave been developed. However, they are generally subject to drawbackssuch as high complexity and manufacturing costs, low reliability andpoor performance, and a lack of capacity for customization or scalingaccording to the requirements of a particular electronic system.

Advances in the medical field have led to an increasing variety andcomplexity of procedures that can be performed using devices that areinserted into the body of a patient. For example, a growing number ofminimally invasive medical and surgical procedures can be performedendovascularly, laproscopically, endoscopically, or robotically usingcatheters, endoscopes and other insertable medical devices. Thesedevices frequently have an electronic component requiring an electricalconnection to external devices that can support a number of discreteelectronic connections or circuits for transmittance of signal andpower. The cables required to make connections to devices insertedwithin a patient or any other remote and/or constrained space, combinedwith the manipulations that may be necessary in the course of performinga procedure, such as twisting or rotational movement of the remotedevice, can lead to twisting, kinking, jamming or similar problems withthe associated electronic cabling. Therefore, a need exists for animproved rotary electrical connector suitable for use in catheters andthe like that would allow for independent rotation of connected deviceswhile providing for uninterrupted electronic signals.

SUMMARY

A rotary electrical interconnect device utilizing components that may bemodularly assembled using simple and robust mechanical connections isdisclosed.

In various embodiments, a rotary device for providing electricalconnections between two or more electronic components includes a rotorassembly and a stator assembly. The rotor assembly may include a rotorshaft, a rotor assembly coupler, and a plurality of slip ring elements.Each slip ring element may further comprise a slip ring mounted on aninsulator disc, with each insulator disc having a slip ring portion witha first circumference, a spacer portion with a second circumferencegreater than that of the slip ring portion, and a hub configured toreceive the rotor shaft and connected to the slip ring portion and thespacer portion by support arms. The rotor assembly may also include aplurality of rotor assembly leads, with each electrically connected to aslip ring. The stator assembly is configured to rotationally engage therotor assembly coupler and includes a stator having a cavity andconfigured to receive the rotor assembly, a plurality of slide contacts,and a plurality of stator assembly leads, each electrically connected toa slide contact. The rotary device may also include a housing configuredto cover the rotary device.

In various embodiments, a rotary device may be configured as acable-to-cable rotary device, a connector-to-connector rotary device, ora connector-to-cable rotary device. A cable-to-cable rotary device mayinclude fittings or other features for attaching a cable sheath to anend of the rotary device housing or to an end of the rotor assembly orstator assembly. A cable-to-cable rotary device may be connected to acable sheath at the rotor end and the stator end of the housing, and therotor assembly leads and the stator assembly leads may extend outwardfrom the rotary device to a remote device or connector through theconnected cable sheath. A connector-to-connector rotary device mayinclude a connector at the rotor end and the stator end of the rotarydevice. The connectors may be electrically connected to the rotorassembly leads and the stator assembly leads and be used to electricallyconnect the rotary device to remote devices using complementaryconnectors. A connector-to-cable rotary device includes both a connectorand a cable sheath connection at ends of the rotary device, as describedabove.

In various embodiments, a method of assembling a rotary device isdisclosed. A method of assembling a customized rotary device based onthe electrical connection requirements of the electronic components tobe connected may include assembling a plurality of slip ring elements,placing the plurality of slip ring elements onto a rotor shaft, securingthe plurality of slip ring elements to form a rotor assembly, assemblinga stator onto the rotor assembly, connecting a plurality of slidecontacts to the stator such that each of the plurality of slide contactselectrically connects to each of the plurality of slip ring elementsrespectively, connecting a plurality of stator assembly leads to theplurality of slide contacts respectively to form a stator assembly, andcovering the stator assembly with a housing.

In various embodiments, a method may also include determining the numberof electrical channels required by the components to be connected, aswell as the electrical specification requirements for each channel. Amethod may further include selecting a rotor assembly and a statorassembly of the appropriate sizes. A method may also include selectingcomponents having the desired ends, such as cable sheath connection endsor connector ends. A method may further include selecting and assemblingthe rotor assembly components into a completed rotor assembly based onthe requirements of the system to be connected, followed by installationof the rotor assembly in the stator. A method may also include assemblyof the stator assembly, attachment of the connector ends, installationof the rotary device housing, and attachment of cable sheath.

BRIEF DESCRIPTION OF THE DRAWINGS

Other systems, methods, features, and advantages of the presentinvention will be or will become apparent to one with skill in the artupon examination of the following figures and detailed description. Itis intended that all such additional systems, methods, features, andadvantages be included within this description, be within the scope ofthe present invention, and be protected by the accompanying claims.Component parts shown in the drawings are not necessarily to scale, andmay be exaggerated to better illustrate the important features of thepresent invention. In the drawings, like reference numerals designatelike parts throughout the different views, wherein:

FIG. 1A is a cut-away side view of a cable-to-cable rotary device inaccordance with various embodiments (cables not shown);

FIG. 1B is an exploded view of a cable-to-cable rotary device inaccordance with various embodiments (cables not shown);

FIG. 2A is a cut-away side view of connector-to-connector rotary devicein accordance with various embodiments;

FIG. 2B is an exploded view of a connector-to-connector rotary device inaccordance with various embodiments;

FIG. 3 is an exploded view of a rotor assembly with 34 slip ringelements in accordance with various embodiments;

FIG. 4A is a perspective view of a front face of a slip ring element anda rotor assembly lead in accordance with various embodiments;

FIG. 4B is an exploded view of a front face of a slip ring elementshowing a terminated rotor assembly lead in accordance with variousembodiments;

FIG. 4C is a perspective view of a rear face of a slip ring elementshowing a terminated rotor assembly lead in accordance with variousembodiments;

FIG. 4D is an exploded view of a rear face of a slip ring elementshowing a terminated rotor assembly lead in accordance with variousembodiments;

FIG. 4E is a magnified view of a front face of a slip ring elementshowing a terminated rotor assembly lead in accordance with variousembodiments;

FIG. 4F is a magnified view of a rear face of a slip ring elementshowing a terminated rotor assembly lead in accordance with variousembodiments;

FIG. 5 is a perspective view of a rotor assembly also showing positionsof corresponding slide contacts from a stator assembly in accordancewith various embodiments;

FIG. 6A is a top view of a partially assembled rotary device inaccordance with various embodiments showing a row of slide contacts andterminated stator assembly leads aligned with odd-numbered slip ringelements of the device;

FIG. 6B is a cross section view of a partially assembled rotary devicein accordance with various embodiments showing a terminated statorassembly lead and the position and orientation of a slide contactaligned with an odd-numbered slip ring element of the device;

FIG. 6C is a bottom view of a partially assembled rotary device inaccordance with various embodiments showing a row of slide contacts andterminated stator assembly leads aligned with even-numbered slip ringelements of the device;

FIG. 6D is a cross section view of a partially assembled rotary devicein accordance with various embodiments showing a terminated statorassembly lead and the position and orientation of a slide contactaligned with an even-numbered slip ring element of the device;

FIG. 7 is a cut-away perspective view of a rotor assembly and statorassembly of a partially assembled rotary device showing a contactbetween a slide contact and a slip ring in accordance with variousembodiments;

FIG. 8A is a perspective view of a stator assembly with a rotor assemblyinserted in accordance with various embodiments;

FIG. 8B is a magnified view of FIG. 8A; and

FIG. 9 is a flowchart of a fabrication process in accordance withvarious embodiments.

DETAILED DESCRIPTION

Referring first to FIGS. 1A-2B, cut-away side views and exploded viewsof rotary devices in accordance with various embodiments are shown.FIGS. 1A and 1B show a cable-to-cable rotary device 100A, and FIGS. 2Aand 2B show a connector-to-connector rotary device 100B. Rotary devices100A and 100B share various features of rotary devices in accordancewith embodiments of the present disclosure that are described in greaterdetail below.

With continued reference to FIGS. 1A-2B, as well as to FIG. 3, a rotarydevice includes a rotor assembly 10. Each rotor assembly 10 includes arotor shaft 11. The shaft may be formed or machined from of any of avariety of suitable materials, including both conductive andnon-conductive materials, for example, metals or metal alloys, ceramics,or plastics. In various embodiments and as illustrated in FIG. 3, arotor shaft 11 may be cylindrical with a substantially smooth or uniformsurface. In other embodiments, the shaft may have features to facilitateoperative connection of the shaft to other components of the rotorassembly or operative connection of the rotor assembly to the statorassembly. For example, the rotor shaft may have one or more longitudinalgrooves, splines, or keys that engage a corresponding pattern in the hubof a slip ring element or other component of the rotor assembly.

Similarly, a rotor shaft may have transverse holes or grooves suitablefor use with various retention devices, such as lock rings, retainingrings, snap rings, circlips, retention pins, or the like, that may beused to retain rotor assembly components such as slip ring elements orbearings on the rotor shaft. In various embodiments and as illustratedin FIG. 3, a rotor shaft 11 may have grooves 12 located adjacent to theends of the rotor shaft that are suitable for use with retaining rings13 which may be used to attach or retain various other components of therotor assembly, such as a bearing 14. In other embodiments, one or bothends of a rotor shaft may be threaded or otherwise shaped or contouredto mechanically engage a complementary portion of a rotary device, suchas by a threaded connection, press-fit, or other interferenceconnection. Rotor shafts having any type of feature suitable forconnecting or engaging any other type of rotor assembly component orrotary device component along its length or at an end are within thescope of the present disclosure.

A rotor assembly 10 may also include a rotor assembly coupler 20connected to an end of the rotor shaft 11. A rotor assembly coupler 20may be substantially cylindrical in shape and define an inner cavitywith a substantially open end oriented outward from the rotary deviceand a second end with an axial hub defining a smaller opening suitablefor receiving an end of a rotor shaft 11. A rotor assembly coupler 20may be connected to a rotor shaft 11 using any suitable means,including, for example, a threaded, press-fit, or other interferenceconnection. As illustrated in the rotor assembly 10 shown in FIG. 3, therotor shaft 11 may be configured with a circumferential groove 12adjacent an end of the shaft which is inserted into the axial hub of therotor assembly coupler 20 and fit with a retaining ring 13 which servesto retain an end of the rotor shaft 11 in the rotor assembly coupler.

A rotor assembly coupler 20 may also include a stator interface portion21 with an outer surface configured to fit an interior portion of thestator 51. The stator interface portion 21 may further include an o-ring22 or other gasket, packing, or seal to sealably engage the innersurface of a stator during rotation of the rotor assembly coupler 20with respect to a stator 51. Similarly, in various embodiments, thestator interface portion 21 of a rotor assembly coupler 20 may serve asa bearing such as an integral plain bearing or friction bearing andprovide a surface for rotational engagement of an interior portion ofthe stator. In other embodiments, a rotor assembly coupler 20 or statorinterface portion 21 may also include a separate bearing to facilitaterotational engagement of a rotor assembly with a stator of a rotarydevice. For example, a rotor assembly coupler may include a bearing,bushing, or the like that mechanically engages a portion of a stator,such as by a press-fit, providing for both axial and radial retention ofa rotor assembly within a stator of a rotary device as well asfacilitating smooth rotational coupling of the components of a rotarydevice.

A surface of rotor assembly coupler 20 oriented toward the interior ofthe rotary device may be used to retain the slip ring elements 30 orother components of the rotor assembly on the rotor shaft 11. Thesurface of the rotor assembly coupler 20 oriented toward the interior ofthe rotary device may also include a feature or features thatmechanically engage the adjacent slip ring elements or other rotorassembly components and prevents them from rotating about the rotorshaft 11 with respect to the rotor assembly coupler 20. This may includeone or more surface projections or depressions configured to engage acomplementary feature of the adjacent rotor assembly component.

The stator interface portion 21 and an attachment portion 23 of therotor assembly coupler 20 may be supported about an axial hub of therotor assembly coupler by two or more support arms extending radiallyoutwardly from the axial hub of the rotor assembly coupler. Spacesbetween the axial hub, the support arms, and the outer circumference ofthe rotor assembly coupler that align with corresponding spaces ininsulator discs or other components of the rotor assembly may permitrouting of rotor assembly leads 37 from the slip ring elements 30 to theinterior of the rotor assembly coupler 20. In various embodiments, theaxial hub and support arms of a rotor assembly coupler may comprise thesurface of the rotor assembly coupler oriented toward the interior ofthe rotary device or may be located near the interior end of the rotorassembly coupler.

A rotor assembly 10 in accordance with various embodiments includes aplurality of slip ring elements 30. In accordance with variousembodiments and as illustrated in FIGS. 3-4D, each slip ring element 30comprises a slip ring 31 and an insulator disc 32. In general, each slipring 31 is a conductive, ring-shaped structure, and each insulator disc32 is a substantially non-conductive, disc-shaped structure thatprovides support for a slip ring 31 with respect to the rotor shaft 11and also provides for electrical isolation of adjacent slip rings 31 inthe rotor assembly 10.

In accordance with various embodiments, each slip ring element of arotary device may have substantially identical physical and electricalspecifications. The modular nature of each slip ring element mayfacilitate assembly of rotary devices comprising a plurality ofphysically and electrically uniform slip ring elements, therebyproviding for uniform and reliable mechanical and electrical performanceof the rotary device.

In various alternative embodiments, a slip ring element may beindividually provided with a particular component (i.e., a slip ring orinsulator disc) or specification to produce a desired electricalperformance for a particular slip ring connection within a rotarydevice. For example, a particular slip ring element may have a slip ringcomprising a conductive material that differs from that of the sliprings of other slip ring elements of the device to provide for aparticular electrical performance specification for the correspondingelectrical connection. Alternatively, a particular slip ring element ofa device may have a different physical specification such as an axiallength of a slip ring portion, an insulator portion, or both, that spansmultiple slide contact positions of a corresponding stator assembly. Inaccordance with various embodiments, the modular nature of the slip ringelements and the rotary devices comprising the slip ring elements mayvariously provide for improved uniformity or improved capacity forcustomization of a rotary device.

In various embodiments, the slip rings 31 of slip ring elements 30 aremade of a metal or metal alloy, for example, copper, beryllium-copper,brass, or the like. The slip rings 31 may be further treated, forexample, by coating with a precious metal such as gold to enhance theconductivity and/or electrical performance of the electrical connectionbetween the slip ring and the slide contact of the stator assembly.Similarly, the slip rings 31 may be polished or otherwise provided withphysical properties or specifications that may enhance the performanceof a slip ring electrical connection, such as by providing for anenhanced signal to noise ratio. The slip rings may be manufactured, forexample, by cutting rings of the desired width from metal tubing havingthe required material and dimensional specifications. In alternativeembodiments, slip rings may be comprised of conductive polymers. Instill other embodiments, slip rings may be manufactured of any materialthat may be provided with a conductive surface, such as by thin filmmetal deposition using any of a variety of chemical or physicaldeposition techniques. Any manner of manufacturing a slip ring from anymaterial or combination of materials to produce a slip ring suitable forconducting electrical signal between a slide contact and a conductorelectrically connected to the slip ring is within the scope of thepresent disclosure.

The insulator disc 32 of each slip ring element 30 is a generallydisc-shaped structure that is substantially non-conductive. As usedherein, the terms “substantially non-conductive,” “insulative,”“dielectric,” and variations thereof may be used interchangeably todescribe a material or structure that generally does not conduct anelectrical current. A substantially non-conductive structure may beconstructed of material that is non-conductive, or may be constructed ofa conductive material such as a metal that is rendered substantiallynon-conductive by treatment of the material or structure, for example,by coating a conductive structure with a non-conductive material.Substantially non-conductive materials may include materials with highresistivity, such as glass, ceramics, polymers, plastics, composites, orthe like.

An insulator disc 32 in accordance with various embodiments comprises aslip ring portion 33 with a first outer circumference and a spacerportion 34 with a second outer circumference that is greater than thefirst outer circumference. The circumferential edge of the insulatordisc 32 in such an embodiment has a “stepped” appearance from a profileperspective (i.e., a two-level outer circumference profile) due to thedifferent diameters of slip ring portion 33 and spacer portion 34 of theinsulator disc. The insulator disc 32 may be substantially cylindricalin shape (i.e., generally having the shape of a right cylinder), forexample, having a slip ring portion side (i.e., front face) and a spacerportion side (i.e., rear face) of the insulator disc that are bothgenerally flat, with the exception of certain features that aredescribed in greater detail herein. In alternative embodiments, theinsulator discs may have shapes or profiles that depart from a generallycylindrical shape and may have, for example, a domed, conical, orirregular shape, while still having a substantially circular crosssection coaxial to the rotor shaft 11 and a two-level outercircumference including a slip ring portion 33 and a spacer portion 34,as described above. Any of a variety of insulator disc shapes orprofiles is possible and included within the scope of the presentdisclosure.

In various embodiments, the slip ring portion 33 and the spacer portion34 of the insulator disc are radially supported about an axial hub 35 bytwo or more radial arms 36. Referring now to FIGS. 4A-4F, various viewsof a slip ring element 30 are shown, illustrating an insulator disc 32having with three radial arms 36 extending from the hub 35 to the slipring portion 33 and spacer portion 34. Spaces 40 between the hub 35, theradial arms 36, and the slip ring portion/spacer portion 33/34 permitrotor assembly leads 37 to be run from each slip ring 31 to the rotorassembly coupler 20, thereby facilitating electrical connection of eachslip ring with the rotor assembly end of a rotary device. An opening atthe axis of the hub 35 of each insulator disc 32 is configured toreceive the rotor shaft 11.

An insulator disc 32 may further include various features thatfacilitate termination of a rotor assembly lead 37 and electricalconnection of the rotor assembly lead to the slip ring 31 of each slipring element 30. In various embodiments and as shown in FIG. 4F, aninsulator disc 32 may include a channel 41 in the spacer portion-sidesurface (i.e., the rear face) of the insulator disc extending from aspace 40 to a terminal penetration 42 through the spacer portion 34. Achannel 41 may be of a suitable width, depth, and configuration toreceive an insulated portion of a rotor assembly lead 37 and tomechanically retain the rotor assembly lead 37, such as by a press-fitinterface (i.e., an interference fit or friction fit). A terminalpenetration 42 through the spacer portion 34 is configured to permit anuninsulated terminal 38 of a rotor assembly lead 37 to pass through thespacer portion 34 of an insulator disc 32 and contact a slip ring 31. Inan assembled slip ring element 30, the terminal 38 of the rotor assemblylead 37 is located between the first outer circumference of the slipring portion 33 of the insulator disc 32 and the inner surface of theslip ring 31. An insulator disc may further include an arcuatedeflection channel 43 located radially inward relative to the firstouter circumference of the slip ring portion 33 and the terminalpenetration 42. A deflection channel 43 permits the portion of theinsulator disc located between the first outer circumference and thedeflection channel 43 to elastically or resiliently flex or deflect toaccommodate a terminal 38 of a rotor assembly lead 37 beneath a slipring 31 while exerting sufficient constant pressure on the terminal 38to maintain the terminal in fixed, electrical contact with the slip ring31. Explained another way, the terminal 38 of a rotor assembly lead 37is electrically connected to the slip ring 31 by a press-fit of the slipring over the first outer circumference of the insulator disc, with theterminal 38 mechanically fixed between the slip ring and the insulatordisc by compression of the terminal between the slip ring 31 and thefirst outer circumference of the insulator disc 32. In variousembodiments, the first outer circumference of an insulator disc mayfurther include a depressed region to accommodate a terminal 38 of arotor assembly lead 37 beneath a slip ring 31.

Other features or configurations for mechanically fixing a terminal of arotor assembly lead in electrical contact with a slip ring are possiblein alternative embodiments. For example, the first outer circumferenceof an insulator disc may include an axial groove of suitable dimensionsfor receiving a terminal and maintaining it in electrical contact with aslip ring, rather than a deflection channel or a depressed region. Inanother example, an insulator disc may include channels, grooves, orpenetrations that permit routing of the terminal of a rotor assemblylead transverse to the axis of the rotor assembly (i.e., parallel to orconcentric with the circumference of the slip ring). Any configurationof an insulator disc that permits routing and securing of a portion of arotor assembly lead and/or terminal with respect to the insulator discand slip ring and that places the terminal in electrical contact withthe slip ring is within the scope of the present disclosure.

Insulator discs may also include structures or features that permit aninsulator disc to operatively engage an adjacent surface. In accordancewith various embodiments and as illustrated in FIGS. 4A-4D, an insulatordisc may have projections 44 extending from a face of the insulator discsuch as the front face of an insulator disc 32. The projections 44 maybe configured to engage an adjacent component of the rotor assembly byfitting within corresponding recesses 45 in the adjacent component, suchas the rear face of another insulator disc 32 or a surface of the rotorassembly coupler. For example, the projections 44 and correspondingrecesses may interface by a press-fit or a snap-fit connection.Projections 44 and corresponding recesses in an adjacent component maybe configured such that an insulator disc 32 is torsionally fixed withrespect to the adjacent component. In this manner, a plurality of slipring elements may be assembled to form a substantially torsionally fixedrotor assembly.

In various embodiments, insulator discs may be formed or manufacturedwith a unitary construction. For example, insulator discs may be moldedfrom a non-conductive thermoplastic resin. In alternative embodiments,each insulator disc may be comprised of multiple, separate componentsthat are joined to form an insulator disc. For example, each insulatordisc may be comprised of a slip ring portion that is separate from thespacer portion. In such an embodiment, separate components of aninsulator disc may be permanently joined, or may be modularly assembledusing features such as the projections and recesses described above.

Slip ring elements are assembled into a rotor assembly 10 by sliding theslip ring elements 30 onto a rotor shaft 11. In the embodimentsillustrated in FIGS. 3-4D, each hub 35 has a circular opening at itsaxis, and the rotor shaft 11 has a circular cross section. The openingat the axis of each hub 35 may be sized such that the opening iscomplementary to the diameter of rotor shaft 11 and the insulator discsslide on freely (i.e., a loose or light interference fit). In otherembodiments, the opening may be undersized with respect to the diameterof rotor shaft 11, such that the insulator discs 32 are press-fit ontothe rotor shaft 11 to provide an interference fit with a suitablestrength of fit to provide resistance to axial and torsional movement ofthe insulator disc relative to the rotor shaft following installation ofthe insulator disc on the rotor shaft. In yet other embodiments, the hubof an insulator disc and the rotor shaft may have other cross sectionalprofiles, such as parallel keyed configurations or the like, thatprovide a hub joint with resistance to torsional movement of aninsulator disc about the rotor shaft while still permitting modularassembly of slip ring elements on the rotor shaft.

In various embodiments, the axial lengths of the slip ring elements orportions thereof in a rotor assembly may vary. For example, the rotarydevices 100A and 100B illustrated in FIGS. 1A-2B each comprise 34uniform slip ring connections. However, a rotary device includingvarious components of the illustrated devices, such as a stator 51, arotor shaft 11 and rotor assembly coupler 20, and housing components,may be configured to have a variety of numbers and configurations ofelectrical connections by varying the configuration of the slip ringelements and the slide contacts.

For example, and with reference to FIG. 4A, insulator discs with varyingaxial lengths (i.e., thicknesses) of the spacer portion 34 may be usedto provide the necessary electrical resistance between adjacent sliprings 31. Varying axial lengths of a spacer portion 34 of a slip ringelement 30 may be produced by using multi-component insulator discshaving multiple, separate spacer portions, or by using insulator discshaving a unitary construction and a range of available sizes withrespect to the axial length of the spacer portion 34.

Similarly, insulator discs with varying axial lengths of the slip ringportion 33 may be used in a rotor assembly. For example, an insulatordisc with an extended slip ring portion 33 may be provided toaccommodate longer slip rings 31 that could be used to make electricalcontact with more than one slide contact to accommodate greaterelectrical current through the slip ring. Varying axial lengths of aslip ring portion 33 of a slip ring element 30 may be produced in amanner similar to that described above with respect to the spacerportion. For example, an elongated slip ring portion of a slip ringelement may comprise three separate slip ring portion components, eachseparately sliding on to rotor shaft 11 and each receiving a rotorassembly lead 37, with an elongated slip ring fitting over the threeslip ring portion components and rotor assembly leads and making contactwith as many as three rotor assembly lead terminals 38 in this example.In this manner, a rotor assembly of the present disclosure may bemodularly or scalably configured, and a rotary device having a varietyof electrical connection configurations may be achieved using variouscombinations of components that can be modularly assembled.

A rotary device in accordance with various embodiments of the presentdisclosure and as illustrated in FIGS. 1A-2B includes a stator assembly50. The stator assembly 50 may comprise a stator 51, a plurality ofslide contacts 52, and a plurality of stator assembly leads 53. Inaccordance with various embodiments, stator 51 is cylindrically shapedand defines a cavity configured to receive a rotor assembly 10.

In various embodiments, the stator 51 of a stator assembly 50 issubstantially non-conductive. A stator 51 may be formed or machined fromof any of a variety of suitable materials, including both conductive andnon-conductive materials, for example, metals or metal alloys, ceramics,or plastics. A stator 51 constructed from a conductive material may berendered substantially non-conductive by coating or otherwise treatingit with a non-conductive material.

A stator 51 may have various features to facilitate operative connectionof the rotor shaft 11. For example, the cavity of a stator 51 mayinclude a bearing configured to receive an end of a rotor shaft 11 andprovide for rotation of the rotor assembly 10 within the stator 51. Theinterior surface of the cavity of the stator 51 may also have dimensionsor features that permit operational engagement of rotor assembly 10. Forexample, the cavity of stator 51 may be configured to receive a bearingor bearings located at one or both ends of the rotor assembly 10, suchas by a press-fit connection, thereby providing for axial and radialretention of the rotor assembly 10, with the bearing or bearingsproviding for rotation of the rotor assembly within the stator.Likewise, the interior surface of the cavity of a stator may beconfigured to engage one or more o-rings or other gaskets, seals, orpackings such that the interior of the rotary device is protected fromexternal fluids or contaminants throughout dynamic interaction (i.e.,rotation) of the rotor assembly with respect to the stator.Alternatively, the interior surface of the cavity of a stator may beconfigured o-rings or other seals. Any of a variety of configurations ofa stator and a rotor assembly that facilitate retention and rotation ofthe rotor assembly 10 within the stator 51, along with sealing of theslip ring connections within the rotary device and protection of theslip ring connections from environmental conditions external to therotary device, are within the scope of the present disclosure.

A stator 51 also includes features for electrically connectingcomponents of the stator assembly 50 to the slip rings 31 of each slipring element in the rotor assembly. With reference now also to FIGS. 7and 8, a stator 51 may include slide contact penetrations 54 forinsertion of each slide contact 52. A stator 51 may also include groovesor channels 55 along the exterior surface of the stator for routing ofthe stator assembly leads 53 from the end of the stator to each slidecontact 52 and for mechanically and electrically connecting a statorlead terminal 56 of each stator assembly lead 53 to each slide contact52. Similarly, portions of the exterior surface of a stator 51 may beconfigured with a relieved region or a decreased diameter to accommodateparallel routing of a plurality of stator assembly leads 53 within astator housing 61.

The channels 55 in a stator 51 may be oriented along circumferentialarcs of the outer surface of the stator and provide for retention of thestator assembly leads 53 and alignment of the stator lead terminals 56with the slide contacts 52 and with the slip rings 31 of the rotorassembly 10. In the embodiment shown in FIG. 8, the lengths of thechannels 55 are progressively longer from the stator end of the stator51 to the rotor end by a distance approximately equal to the distancebetween every other slip ring of the rotor assembly. Such aconfiguration permits orderly parallel routing of stator assembly leadsthat terminate at a row of slide contacts running parallel to the axisof the rotary device.

The stator assemblies 50 illustrated in FIGS. 1B and 2B each include tworows of slide contacts oriented substantially perpendicularly to theaxis of the rotary device and on opposite sides of stator 51, with theslide contacts 52 in each row aligning with every other slip ring 31 inthe rotor assembly 10. This arrangement of the slide contacts 52 withrespect to the slip ring elements of a rotor assembly in accordance withvarious embodiments is illustrated in greater detail in FIGS. 5-6D. FIG.5 shows a perspective view of a rotor assembly in accordance withvarious embodiments and the relative positions of slide contacts 52arranged in two rows on opposite sides of the rotor assembly with thestator removed for purposes of illustration. FIGS. 6A-6D illustrate apartially assembled rotary device in accordance with various embodimentsshowing two rows of slide contacts 52 on opposite sides of the stator,with the top view (FIG. 6A) showing slide contacts aligned withodd-numbered slip ring element positions and the bottom view (FIG. 6C)showing slide contacts aligned with even-numbered slip ring elementpositions of the rotary device. FIGS. 6B and 6D illustraterepresentative cross-section views of a rotary device at an odd-numberedslip ring element position and an even-numbered slip ring elementposition, respectively, to show the relative position and orientation ofa slide contact 52 and a slip ring 31. Such an even radial and axialdistribution of slide contacts within a rotary device may provide for asymmetrical or balanced distribution of frictional and/or pressureforces between the stator assembly and the rotor assembly. However,stators having any number of rows of slide contacts distributedsymmetrically or asymmetrically about the circumference of the statorand having slide contacts aligned with slip rings in any possiblesequence are within the scope of the present disclosure. Likewise,stators having slide contacts arranged in other patterns, such asspirals or other non-linear patterns, are also within the scope of thepresent disclosure.

Referring again to FIGS. 7-8, a portion of each stator assembly lead 53adjacent to the stator lead terminal 56 of the lead and fitting inchannel 55 may be mechanically fixed in the channel 55 using aninterference fit such as a series of alternating projections 57 in theside wall of each channel. The stator lead terminal 56 of each statorassembly lead 53 may be likewise mechanically secured by andelectrically connected to a slide contact 52 by insertion of the slidecontact into a slide contact penetration 54 in the wall of the stator51. A fixed end of each slide contact is press-fit into a slide contactpenetration 54 and retained in position by an interference fit. Thefixed end of each slide contact 52 retains the stator lead terminal 56between a bend or curve of the fixed end of the slide contact and aportion of the exterior surface of the stator. In other embodiments,each stator lead terminal 56 may further be press-fit into a channelapproximating the size of the terminal.

A free end of each slide contact 52 extends into the cavity of stator 51and makes contact with a slip ring 31, as shown in FIG. 7. The slidecontacts 52 may be biased to maintain mechanical contact and anelectrical connection with the slip rings 31 by the orientation of theslide contact penetrations 54 and/or the configuration of the slidecontacts 52. For example, the slide contacts 52 may be configured sothat they are resiliently biased toward the slip rings 31 afterinstallation in the stator 51. The slide contacts are constructed of aconductive material and may be formed, for example, of a wire bent orformed to a suitable configuration or by cutting, stamping, or etchingfrom a sheet of material. The free end of each slide contact 52 may besubstantially straight, contacting a slip ring tangentially asillustrated in FIG. 7, or the free end of each slide contact may have anarc or bend that corresponds to a portion of the circumference of a slipring and increases the contact area between the slip ring and the slidecontact.

A rotary device in accordance with various embodiments includes ahousing configured to cover or encase the device. A housing may beconfigured to protect the rotary device and the electrical connectionstherein from the external environment. A housing is generallynon-conductive, and may be constructed of a material that issubstantially non-conductive or may be constructed of a conductivematerial that is treated to render the housing substantiallynon-conductive. Referring again to FIGS. IA-2B, a housing may becomprised of one or more components, such as a stator housing 61 and/ora rotor assembly coupler overmold 62. In alternative embodiments, aportion of a rotary device or rotary device component, such as a portionof an external surface of a rotor assembly coupler, may comprise aportion of the external surface of the finished device without beingfurther covered by or encased in a housing component such as a rotorassembly coupler overmold.

In various embodiments, a stator housing 61 may be constructed as aunitary piece, as illustrated in FIGS. 1A and 1B, and configured toreceive a stator assembly 50 and to retain the stator assembly by athreaded connection, press-fit, snap-fit, or other interference fittingof the stator housing over the stator assembly. In other embodiments andas illustrated in FIGS. 2A and 2B, a stator housing 61 may comprisemultiple pieces that are fit together over a stator assembly 50 andjoined by any of a variety of suitable means, such as by a snap-fit,adhesive connection, welded connection, or the like. The stator 51and/or stator housing 61 may further include one or more o-rings 58 orother gaskets, seals, or packings to provide a seal between the statorassembly and the stator housing at one or both ends of the stator and toprevent external fluids or other contaminants from contacting the statorassembly. In various embodiments, a stator housing 61 may also providefor further retention of the slide contacts 52 in the slide contactpenetrations 54 of the stator and help to maintain mechanical andelectrical contact of the fixed end of the slide contacts with thestator lead terminals 56.

Similarly, rotor assembly coupler 20 of rotor assembly 10 may be encasedby a rotor assembly coupler overmold 62. A rotor assembly couplerovermold 62 may be configured and attached to the rotor assembly coupler20 or to the attachment portion 23 of a rotor assembly coupler in amanner similar to that described above for a stator housing 61.

A stator housing 61 may be configured for attachment to a sheath,housing, or other external protective covering of a multi-conductorelectrical cable. For example, and as illustrated in the cable-to-cablerotary device 100A shown in FIGS. 1A and 1B, a stator housing 61 mayterminate in a male press-fit cable sheath connection 63 resembling ahose barb fitting over which a cable sheath (not shown) may be fit toprovide a sealed connection between the rotary device 100A and anelectrical cable to a remote device. Likewise, the rotor assemblycoupler overmold 62, rotor assembly coupler 20, or attachment portion 23of a rotor assembly coupler may be similarly configured to accept anelectrical cable sheath (not shown). In the illustrated rotary device100A, rotor assembly coupler 20 is configured to receive a cable withinthe cavity of the rotor assembly coupler.

In cable-to-cable rotary device embodiments, wire leads from the rotarydevice extend outward from the device to remote devices, connectors, orother components. For example, rotor assembly wire leads 37 may extendoutwardly from the rotor end of the cable-to-cable rotary device 100Athrough an attached cable sheath (not shown) to a first remoteelectronic device. Likewise, stator assembly leads 53 may extendoutwardly from the stator assembly end of the rotary device 100A throughan attached cable sheath (not shown) to a second remote electronicdevice. In this manner, rotary device 100A can permit a first remoteelectronic device and a second remote electronic device to be rotatedfreely with respect to one another without twisting or binding of the ofthe connecting cable while maintaining a continuous electricalconnection across multiple electrical channels.

In various embodiments, a rotary device may include connectors (i.e.,male plug connectors, female socket or receptacle connectors, or anytype of device for providing an interface between electrical circuitsusing a mechanical assembly) at one or both ends of the rotary devicefor making electrical connections between the rotary device and remoteelectrical devices. For example, and as illustrated in FIGS. 2A and 2B,a connector-to-connector rotary device 100B may comprise a male plugconnector 71 on the stator end of the rotary device and a femaleconnector 72 on the rotor end of the rotary device. The connectors maybe configured to support multiple discrete electrical channels that maybe electrically connected to the rotor assembly leads (not shown) for aconnector at the rotor end or to the stator assembly leads 53 at thestator end. In accordance with various embodiments, connectors may beselected or configured to provide for resistance to entry of fluid orother external contaminants and be suitable for use, for example,intraluminally or intravascularly. A first remote electronic device maybe connected to the male plug connector 71 of rotary device 100B, and asecond remote electronic device may be connected to the female connector72 using corresponding mateable connectors. In this manner, rotarydevice 100B can permit a first remote electronic device and a secondremote electronic device to be rotated freely with respect to oneanother without twisting or binding of the of the connecting cable whilemaintaining a continuous electrical connection across multiple channels.

In accordance with various embodiments, any type of connector thatpermits parallel conduction of separate electrical channels through theconnector, such as a multi-pin connector, may be used. A wide variety ofconnectors are known to persons of ordinary skill in the art, includingsuch connectors as are described and illustrated in U.S. Pat. Nos.7,326,091, 7,661,995, 7,938,670, D596,127, D615,932, and D616,825, whichpatents are hereby incorporated by reference in their entireties.Likewise, the illustrated rotary device configuration shown in FIGS. 1Band 2B having a male plug connector at one end and a female connector atthe other end of the rotary device is for purposes of illustration only.In accordance with various embodiments, any type of connector orcombination of connectors may be used at the ends of a rotary devicewithout limitation to any particular combination of connector gender ortype. Likewise, a rotary device may have a connector at one end and acable connection at the other end. Rotary devices having any of therange of possible permutations of the various end configurationsdescribed above are within the scope of the present disclosure.

In a rotary device comprising one or more connectors, either the rotorassembly leads 37, or the stator assembly leads 53, or both, mayterminate at and electrically connect to the connectors at therespective ends of the device in any suitable manner. Likewise, theconnectors may be connected to the rotor assembly coupler 20 or the endof the stator 51 opposite the rotor assembly coupler 20 using anysuitable means, for example, a press-fit, threaded fit, bayonetconnector, or any other interference, welded, brazed, or adhesive fit.The interface between the stator 51 or rotor assembly coupler 20 and aconnector may be configured such that mechanical attachment of theconnector simultaneously provides for electrical connection of thestator assembly leads 53 or the rotor assembly leads 37 to the attachedconnector. In other embodiments, electrical connection of the leads to aconnector may be made separately from attachment of the connector to thestator assembly end or rotor assembly coupler using any suitable means,either before or after attachment of the connector to the statorassembly end or the rotor assembly coupler.

In accordance with various embodiments, a rotary device may be suitablefor use in a medical device. For example, a rotary device as disclosedherein may be used to electrically connect a first remote electronicdevice that may deployed in the body of a human patient to a secondremote electronic device that may remain outside of the body of thehuman patient. Various medical devices, such as an electronicinstrument, apparatus, or implant deployed within a body lumen or cavitymay require rotation during insertion or operation while attached to anexternal electronic device such as a power source, monitor, datarecorder, or computer by an electrical cable. In such a scenario, theability to freely rotate the first remote electronic device whilecontinuously maintaining an electrical connection with the externalelectronic device and without twisting, kinking, binding or jamming ofthe connecting electrical cable due to rotation of the first electronicdevice during a medical procedure is desirable.

Rotary devices in accordance with various embodiments disclosed hereinmay be suitable for use in medical facility such as a hospital oroperating room or other patient care or diagnostic facility. Forexample, a rotary device may be compatible with the electronicperformance requirements of any type of electronic device, including anytype of medical electronic device, with respect to specifications suchas current, voltage, impedance, and signal to noise ratio. A rotarydevice in accordance with various embodiments may be configured withcomponents having specifications suitable for low voltage/low amperagecurrent and signal transmission with low noise and high signal quality.Similarly, a rotary device may provide the physical performancespecifications required in various medical settings, including, forexample, resistance to entry of water or other fluids and the ability tomeet regulatory requirements for single use and/or reusable devices withregard to cleanliness or sterilization. The rotary devices disclosedherein may also provide an ability to meet other physical requirementsassociated with medical device applications such small size andbiocompatibility.

In accordance with various embodiments, a method of assembling acustomized rotary device based on the electrical connection requirementsof the components to be connected is provided. A method of assembling acustomized rotary device may comprise steps of determining the number ofelectrical channels required by the components to be connected, as wellas determining the electrical specification requirements for eachchannel. A method may further include selecting a rotor and statorassembly of the appropriate size, including the appropriate length anddiameter. Likewise, the method may comprise selecting a rotor and statorassembly having the desired ends, such as cable ends or connector ends,based on the manner in which the rotary device will be attached to theremote components of the system. The connector ends or cables may beattached to the rotor and stator as described above. A method mayfurther comprise attaching connectors to the electrical cables of thecomponents to be connected, wherein the connectors correspond to or arecompatible with connectors of the rotary device or connectors that maybe located at the remote ends of cables extending from the rotarydevice.

Following determination of the number of electrical channels andselection of the rotor assembly and stator assembly components, therotor assembly may be assembled. FIG. 9 presents a flowchart 900 of amethod of assembling a rotary device, such as the rotary devices 100Aand 100B. At 910, slip ring elements are assembled, such as the slipring 31. At 920, slip ring elements are placed onto a rotor shaft, suchas the rotor shaft 11. Slip ring elements may be added to the rotorshaft and connected to a rotor assembly lead as disclosed herein. Thenumber and configuration of the slip ring elements, including the axiallength (i.e., thickness) of the spacer portion and/or the axial lengthof the slip ring may be varied or selected based on the electricalperformance requirements of the system connected by the rotary device.For example, an insulator disc with an increased axial length of thespacer portion may be selected to provide greater isolation of adjacentslip rings that may carry greater current or power. Similarly, longerslip rings may be selected and installed in connection to multiple rotorassembly leads and making contact with multiple slide contact such thatthe same electrical signal is carried by multiple parallel leads in theconnected system. At 930, slip ring elements are secured to form a rotorassembly, such as the rotor assembly 10. As each slip ring element isadded, rotor assembly leads are routed through the spaces in theinsulator discs and the terminals are connected to the insulator discand the slip rings as described above. Portions of the length of therotor assembly that are not required for making an electrical connectionmay be occupied by installing a spacer element of the appropriate lengthon the rotor assembly.

Following assembly of the rotor assembly, a stator, such as the stator51, is assembled. At 940, the stator is assembled onto the rotorassembly. At 950, slide contacts, such as the slide contacts 52, areconnected to the stator to electrically connect to the slip ringelements. At 960, stator assembly leads, such as the stator assemblyleads 53, are connected to the slide contacts to form the statorassembly, such as the stator assembly 50. Stator assembly leads arerouted along the outer portion of the stator and fixed in channels, andslide contacts are inserted into slide contact penetrations tomechanically secure and electrically connect the stator assembly leadterminals to the slide contacts. Slide contacts are inserted inpositions in the stator corresponding to the appropriate slip rings ofthe rotor assembly and in the desired row, for example, to maintain asymmetrically balanced distribution of slide contacts about the rotorassembly.

At 970, the stator assembly is covered with a housing or overmold, suchas the overmold 62. Following insertion of the slide contacts androuting and connection of the stator assembly leads, the stator housingand the rotor assembly coupler overmold may be attached to the rotarydevice. In various embodiments, the assembled rotary device may bepackaged and sold in various configurations of cable-to-cable rotarydevices, connector-to-connector rotary devices, or connector-to-cablerotary devices for installation in an electronic system by an end useror third party. In other embodiments, a rotary device may be connectedto or installed in an electronic system, for example, by the rotarydevice manufacturer or assembler.

Rotary devices in accordance with various embodiments as describedherein and methods of assembling the same may provide various benefitssuch as modularity and scalability that facilitate their application oruse in a variety of systems and environments, as well as providingfurther benefits such as improved simplicity, reliability, and ease ofmanufacturing and assembly with respect to prior art devices andmethods.

As used herein, the terms “rotor” and “stator” are applied for the sakeof clarity and convenience with respect to components of the rotarydevices described herein that are coupled in a rotationally operativemanner. The term “stator” as used in the present disclosure is notlimited to a fixed or non-moving portion of a rotary device. Rather,both the stator assembly and the rotor assembly of a rotary device asdisclosed herein may rotate with respect to an external point ofreference as well as with respect to each other.

As used herein, the term “remote” is used to refer to a device orconnection that is located external to a rotary device at any distancefrom a rotary device.

Although the various rotary devices illustrated and described herein areshown as having various combinations of cable ends, male connector ends,or female connector ends, rotary devices having any suitable combinationof cable and/or connector end, along with any combination of type orgender of connector end, are within the scope of the present disclosure.Likewise, the embodiments illustrated herein depicting rotary deviceshaving a particular number of uniform slip ring electrical connectionsare for purposes of illustration only, and alternative embodimentsutilizing greater or fewer slip ring connections or non-uniform slipring connections are within the scope of the present disclosure.

Various embodiments of the invention have been disclosed in anillustrative style. Accordingly, the terminology employed throughoutshould be read in a non-limiting manner. Although minor modifications tothe teachings herein will occur to those well versed in the art, itshall be understood that what is intended to be circumscribed within thescope of the patent warranted hereon are all such embodiments thatreasonably fall within the scope of the advancement to the art herebycontributed, and that that scope shall not be restricted, except inlight of the appended claims and their equivalents.

What is claimed is:
 1. A rotary device comprising: a rotor assemblyhaving: a rotor shaft, a rotor assembly coupler, a plurality of slipring elements, each slip ring element comprising a slip ring and aninsulator disc having a slip ring portion with a first outercircumference, a spacer portion with a second outer circumferencegreater than the first outer circumference, and a hub configured toreceive the rotor shaft and connected to the slip ring portion and thespacer portion by at least two support arms, and a plurality of rotorassembly leads, each electrically connected to a slip ring; a statorassembly configured to rotationally engage the rotor assembly couplerand having: a stator having a cavity therein and configured to receivethe rotor assembly, a plurality of slide contacts, each mechanicallyconnected to the stator and configured to electrically connect to arespective slip ring of the plurality of slip ring elements, and aplurality of stator assembly leads, each electrically connected to arespective slide contact; and a housing having a stator housing and arotor assembly coupler overmold, wherein the housing is configured tocover the rotary device.
 2. The rotary device of claim 1, the rotorassembly further comprising bearings.
 3. The rotary device of claim 1,wherein the rotor assembly leads are disposed through the rotor assemblyin a space defined by the hub, the support arms, the slip ring portion,and the spacer portion of the insulator discs.
 4. The rotary device ofclaim 1, wherein a surface of the insulator disc is configured tooperatively engage an adjacent surface.
 5. The rotary device of claim 1,the insulator disc further comprising a projection configured tooperatively engage a recess in a corresponding surface.
 6. The rotarydevice of claim 1, the insulator disc further comprising a channel in aface of the insulator disc, wherein the channel is configured to receivea portion of a rotor assembly lead.
 7. The rotary device of claim 1,wherein the insulator disc is of unitary construction.
 8. The rotarydevice of claim 1, wherein the slip ring portion and the spacer portionare separate components.
 9. The rotary device of claim 1, wherein arotor assembly lead is electrically connected to a slip ring by apress-fit connection.
 10. The rotary device of claim 1, wherein a slipring element further comprises an insulator disc having a deflectionchannel and a first outer circumference with a depressed region adjacentto the deflection channel, and wherein a rotor assembly lead iselectrically connected to a slip ring of the slip ring element bycompression of a terminal of the rotor assembly lead between the firstouter circumference at the depressed region and the slip ring.
 11. Therotary device of claim 1, wherein a slide contact is connected to thestator by a press-fit connection.
 12. The rotary device of claim 1,wherein a slide contact is electrically connected to a stator assemblylead by a press-fit connection.
 13. The rotary device of claim 1,wherein the rotor assembly coupler further comprises a connectorelectrically connected to the rotor assembly leads.
 14. The rotarydevice of claim 1, wherein an end of the stator assembly furthercomprises a connector electrically connected to the stator assemblyleads.
 15. The rotary device of claim 1, wherein each slip ring iselectrically connected with at least one slide contact.
 16. The rotarydevice of claim 1, wherein the plurality of slide contacts have an evenradial and axial distribution about the rotor assembly.
 17. A rotarydevice comprising: a rotor assembly having: a rotor shaft, a rotorassembly coupler, a plurality of slip ring elements, each slip ringelement comprising a slip ring and an insulator disc having a slip ringportion with a first outer circumference, a spacer portion with a secondouter circumference greater than the first outer circumference, and ahub configured to receive the rotor shaft and connected to the slip ringportion and the spacer portion by at least two support arms, and aplurality of rotor assembly leads, each electrically connected to a slipring; a stator assembly configured to rotationally engage the rotorassembly coupler and having: a stator having a cavity therein andconfigured to receive the rotor assembly, a plurality of slide contacts,each mechanically connected to the stator and configured to electricallyconnect to a respective slip ring of the plurality of slip ringelements, and a plurality of stator assembly leads, each electricallyconnected to a respective slide contact; a housing having a statorhousing and a rotor assembly coupler overmold, wherein the housing isconfigured to cover the rotary device; and a first connector forelectrical connection connected to the plurality of rotator assemblyleads; and a second connector for electrical connection connected to theplurality of stator assembly leads.
 18. A method of assembling a rotarydevice comprising: assembling a plurality of slip ring elements; placingthe plurality of slip ring elements onto a rotor shaft; securing theplurality of slip ring elements to form a rotor assembly; assembling astator onto the rotor assembly; connecting a plurality of slide contactsto the stator such that each of the plurality of slide contactselectrically connects to each of the plurality of slip ring elementsrespectively; connecting a plurality of stator assembly leads to theplurality of slide contacts respectively to form a stator assembly; andcovering the stator assembly with a housing.
 19. The method of claim 18,further comprising determining a number of slip ring elements based onan electrical performance requirement for the rotary device.
 20. Themethod of claim 18, further comprising electrically connecting a firstconnector or a first cable to the plurality of slip ring elements andelectrically connecting a second connector or a second cable to theplurality of stator assembly leads.